cooling VOLVO 960 1982 Service Repair Manual

70019401960 Specifications
Section 2 B 19, B 23 Engines
Section 2 B 19, B 23 Engines
Group 20 General ................................ 15
Group
21 Engine assembly ........................ 16
Group 22 Lubricating system
....................... 20
Group 23 Fuel system ............................ 21
Group 25 Intake and exhaust systems .............. 31
Group 26 Cooling system .......................... 32
Group 28
Ignition system .......................... 33
j'"
I.t
Group 20 General ~ :,
129750
Performance , compression ratios, octane requirements
Engine Remarks Compres-Octane
Output Max torque
type sion
ratio r
equire-
ment
kWat hp at
r/s r/min
819E 10.0:1 98 86/100
117/6000
819ET 7.5:1 98 110/92
150/5500
823E Scandinavia, Switzerland 10.3:1 96 95/88 129/5250
Other markets 10.0:1 98 96/90 131/5400
823ET 9.0:1 981 127/95 173/5700
823FT 8.7:1 912
• 3 117/88 160/5300
1575/5300
1) Australia 97-98 octane 2) Unleaded
petrol (gasoline) 91 octane RON (Research Octane Number). AKI = 87, according to R+2M where M stands for Motor Octane Number
. "
Nm at
r/s
158/50
230/60 190/50
190/60
250/57
250148
3) Fill with premium unleaded petrol (gasoline) (AKI = 91) to improve performance and driveability at altitudes in excess of 2000 It (600 m) in warm climates 4) Ft Ib 5) Horse power.
Other general data
No. of cylinders ............................................. .
Bore .
............................................. .. mm (in)
Stroke ..
.... ......................................... mm (in)
Displacement. ...................................... dm3 (litre)
Firing order ................................................. .
Compression pressure1) ..
............................ MPa (psi)
Max . deviation between
cylinders ................... MPa (psi)
Approx. weight.
............... ........... ..... ......... kg (Ib)
Turbocharged versions ................................. kg (Ib)
1) With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 r/min).
819
4
88.9
(3.503)
80 (3.152)
1.99
1-3-4-2
0.9 (128)
0 .2 (28)
165 (363)
170 (375)
823
4
96 (3.782)
80 (3.152)
2.32 1-3-4-2
0 .9 (128)
0 .2 (28)
165 (363)
170 (375)
kpm at
r/min
16.1/3000
23.4/3600
19.4/3000
19.4/3600
25.5/3400
25.5/2900 184
4/2900
15

70019401960 Specifications
Section 2 B 19, B 23 Engines
General
Group 26 Cooling system
128187
Coolant - composit ion -guarantee
Since aluminium is used in the engines, active corrosion
protection
is necessary in the coolant to help prevent corro­
sion damage.
Use genuine
Volvo coolant, type C (blu e-green), diluted
with clea n water in proportions of SO/50. This mixture helps
to prevent corrosion and frost damage.
• Never top-up the cooling system with water alone. Use
genuine
Volvo coolant diluted with clean water in propor­
tions of 50/50.
•
The coolant should be changed every 40,000 km
(25,000 miles) since the corrosion-protective additives in
the coolant lose their effect in time.
• The cooling system should be cleaned using solvent
PIN 1 161 328-8 prior to filling new coolant.
Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . approx 9.5 litres (10.05 US qts)
Expans ion tank
Pressure valve in filler cap opens at:
overpressure
........ ' ..................................... .
underpressure .
.............................. --: ............ .
Thermostat
Marking .................................................... .
Starts to open
at ............................................ .
Fully open at ...................................... ......... .
Fan belts
Designation (Volvo PIN), early type ..... : ...................... .
late type ............................. .
32
65-85 kPa (9.2-12 psi)
7.0 kPa (1.0 psi)
Type 1
87
86-88°C
(187-190°F)
9rC (207°F)
1983
HC 38x925
HC 38 cogX925
Type 2
92
91-93°C
( 196-199°F)
102°C (216°F)
1984
HC 38x913
HC 38 cogX913

(
70019401960 Specifications
Section 2 B 200, B 230 Engines
Section 2 B 200, B 230 Engines
Group 20 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31
Group 21 Engine block ........................... 32
Group
22 Lubricating system ....................... 38
Group
23 Fuel system ......... ................ .. 39
Group
25 Intake and exhaust systems. . . . . . . . . . . .. 60
Group 26 Cooling system. . . . . . . . . . . . . . . . . . . . . . . .. 62
Group
28 Ignition system. . . . . . . . . . . . . . . . . . . . . . . .. 63
..... 1/
j. Group 20 General
Performance , compression ratio, octane requirements
Engine Remarks Compres-
type slon ratio
B200K Europe, manual 10.0 automatic 10.0 Overseas
8.5
B200 E 10
.0
B200 F 1990 10.0 1991 10.0
B200ET 8.5
B204
E 9.7
B204FT / 8.2
B204GT 8.2
B230A Scandinavia 10 .3
B230K -1986 Europe 10.3 Overseas 9.0 1987-10.5
B230 E 10.3
B230ET 9
.0
B230 F USA, Canada 9
.8 Other markets 9.8
B230FB 9.3
B230 FT USA , Canada, Japan -1989 8.7 Other markets -1989 8 .7
USA, Canada 1990-8.7 Other markets 1990-8.7
B230GT 8.7
B234F USA, Canada 10.0
B234 F IG Other markets 10.0
LH-drive, man gearbox -1989 10.0
11 Unleaded fuel can also be used . 21 Unleaded fuel only. 91 octane unleaded fuel can be used. 31 Horse power. 41 Ft lb.
•
RON stands for Resea rch Octane Number, and is a measure of
the ability of a fuel to withstand knocking. MON stands for Motor Octane Number and is another way of
measuring the same property.
(R+M)/2,
also called AKI (Anti Knock Index) combines these two
m eas urem ents .
95
RON is equivalent to 91 (R+M)/2. 91 RON i s equivalent to 87 (R+M) /2.
Octane Output Max torque require-ment kWat hp at Nm at RON" rls
r/min rls
98 76/90
103/5400 165/45 98 78/90 106/5400 170/45 93 74/90 100/5400 165/45
95 1
.
71 89/95 121/5700 158/80
9521 80/98 110/5900 155/48 9521 82/95 11115700 158/57
98
118/92 160/5500 245/58
9511 102/100 139/6000 181/80
952
) 140/88 190/5300 280/49
9511 147188 200/5300 290/49
98 82/83 112/5000 192/42
98 84/87
114/5200 192/42 9311 80/87 109/5200 185/42 9511 86/87 117/5200 194/42
95 1
.
71 96/92 131/5500 190/55
98 134/97 182/5800 260/57
9521 85/90 11431/5400 183/4251
9521 85/90 116/5400 183/4251
9521 96/92 130/5500 185/49
9521 119/88 16031/5300 253/48 9521 115/80 156/4800 242/55 9521 121180 16231/4800 264/57 9521 121/80 165/4800 264/57
9511 125/80 170/4800 265/57
9521 114/95 15331/57 00
203/75
952
.81 114/95 155 /5700 203/75
9521 117/97 159/5800 210/74
51 With Regina-Re x I: 182/42 .
61 With Regina-Rex I: 134/2500 and 18.6/ 2500 . 71_1986: 98 octane .
81 B 234 G: Leaded fuel can be used .
~ ""
129750
kpm at r/min
16.8/2700
17.3/2700
16 .8/2700
16 .1/4800
15 .8/2900
16.1/2800
25 .0/3500
18.4/4800
28 .5/2950
29 .6/2950
19 .6 /2500
19.6/2500 18 .9 /2500 19 .8/2500
19.4/3300
26.5/3400 135
41/250061
18.7/250061
18 .9/2950
18rl/2900
24.7/3300
19541/3450 26 .9 /34 50
27.0/3450
150
41/ 4450
20 .7/4450 21.4/4450
35
I
I
I
I
I
I
I
""
III
III· III
III· ·111 III '111 III

70019401960 Specifications
Section 2 B 200, B 230 Engines
General
Expansion tank
Group 26 Cooling system
128187
Coolant -composition -guarantee
Since aluminium is used in the engines, active corrosion
protection is necessary
in the coolant to help prevent corro­
sion damage.
Use genuine
Volvo coolant, type C (blue-green), diluted
with clean water in proportions of 50/50. This mixture helps
to prevent corrosion and frost damage .
• Never top-up the cooling system with water alone. Use
genuine
Volvo coolant diluted with clean water in propor­
tions of 50/50 .
•
The coolant should be changed every 25,000 miles
(40,000
km) since the corrosion -protective additives in
the coolant lose their effect in time.
• Clean cooling system with solvent (P/N 1161328-8
prior to
filling new coolant.
Capacity, B 200/230. . . . . . . . . . . . . . . . . . approx 8.5 litres
US qts 9.0
B 204/234. . . . . . . . . . . . . . . . .. approx 9.5 litres
US qts 10.0
Pressure valve
in filler cap opens at;· . kPa psi
11
14
21
1.0
overpressure, early type .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
late type without turbo . . . . . . . . . . . . . . . . . . . . . . . . . 100
with turbo and B 204/234. . . . . . . . . . . . . . . 150
underpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 .0
Thermostat
Marking ............................ ........................ .
Starts to open
at ......... .............. ..................... .
Fully open at ............................................... .
66
Type 1
87
86-88 °C
(187-190 °
F)
9rC
(20rF)
Type 2
92
91-93°C
( 196-199 °F)
102°C
(216 °
F)

70019401960 Specifications
Section
2 B 28 Engine
Section 2 B 28 Engine
Group 20 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 69
Group 21 Engine................................ 70
Group 22 Lubricating system ...................... 74
Group 23 Fuel system ............ . . . . . . . . . . . . . .. 75
Group 25
Intake and exhaust systems ............. 82
Group 26 Cooling system ......................... 83
Group 28
Ignition system. . . . . . . . . . . . . . . . . . . . . . . .. 84
129756
Group 20 General
Performance, compression ratios, octane requirements
E ngine Compression Octane
type ratio r
eq
uirement
B28A 8.8:1 91-93
B28E 9 .5 :1 981
)
B28F 8.8 :1 912
)
1) Australia 97-98 octane 2) According to research method (RON). Unleaded gasoline
According to formula (R+M/2) = 87 octane 3) ft. lb. 4) Horse power
Other general data
kWat
rl s
96/88
115/95
100/92
Number of cylinders ......................................... .
Bore
.............. ......................................... .
Stroke ................ " ................................... .
Displacement ............................................... .
Firing order
................................................. .
Compression
(normal rating)l) ........................... ..... .
Weight, approx
................ ............................. .
I) With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 r/min).
Output
hp at
r/min
130/5250
156/5700
136/5500
134
4)/5500
6
91 mm (3.582 in)
73 mm (2.874 in)
2 .849 dm3 (Iitres)
1-6-3-5 -2-4
Nm at
rl s
212150
235/50
215/46
0.8-1 .1 MPa (114-156 psi)
150 kg (330 Ib)
/ ......
l.t
~ '
129750
Max torque
kpm at
r/min
21.6/3000
24.0/3000
21. 9/2750
1593)/2. 700
69
"' '" ill
,' ....
N,'
'" III

(
General
70019401960 Specifications
Section
2 B 28 Engine
Group 26 Cooling system
128187
Coolant -composition -guarantee
Since aluminium is used in the engines, active corrosion
protection is necessary
in the coolant to help prevent corro­
sion damage .
Use genuine
Volvo coolant, type C (blue-green ) diluted
with clean water in proportions of 50/50. This mixture helps
to prevent corrosion and frost damage.
• Never top-up the cooling system with water alone. Use
genuine
Volvo coolant diluted with clean water in propor­
tions of
50/50.
•
The coolant should be changed every 25,000 miles
(40,000
km) since the corrosion-protective additives in
the coolant lose their effect in time.
• Clean cooling system with solvent (P/N 1161328-8)
prior to
filling new coolant.
litres
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0
US qts
10.5
Expansion tank
Pressure valve in cap opens at:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kPa
overpressure, early type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
late type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
underpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.0
Thermostat
Marking .................................................... .
Starts opening
at. ........................................... .
Fully open at ............................................... .
Fan belts
Designation, type 1 ..... : ................................ .... .
type
11. ..................•......•................
type III (not B 28 F USA) ......................... .
92
91-93°C (196-199°F)
102°C (216°F)
HC 38 x 1100
HC 38 cog x 1100
HC 38 cog x 1075
psi
11
21
1.0
83
til ·tt til II III '11 III ·tt II'

70019401960 Specifications
Section 2 B 280' Engine .
Section 2 B 280 Engine
Group 20 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Group
21 Engine..... ................. .......... 87
Group
22 Lubricating system. . . . . . . . . . . . . . . . . . . . .. 92
Group
23 Fuel system ........................ ... 93
Group
26 Cooling system ......................... 96
Group
28 Ignition system. . . . . . . . . . . . . . . . . . . . . . . .. 97
Group 20 General
Performance , compression ratios, octane requirements
Engine Compression Octane
type ratio
requirement
kW'a t
rls
B28 0E
Sca ndinavia 10.0:1 Min 951
) 115/88
B280 E r
Other markets 10 .0:1 Min 951
) 125/90
B280 F 9.5:1 Min 912
) 108/85
1) Unleaded fuel can be used 2) Unleaded fuel only 3) Horse power 4) Ft lb.
Other general data
Number of cylinders ................. ........................ .
Bore
.. ............................ ......................... .
Stroke ............................................... ...... .
Displacement
............................................... .
Firing order .
.................................. .' ............. .
Compression (normal
niting)l) ................................ .
Weight, approx ..
.................. ......................... .
1) With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 r/min).
86
Output
hp at
r/min
156/5250
170/5400
147/5100
145/5100
3
6
91 mm (3. 582 in)
73 mm (2.874 in)
2.849 dm3 (Iitres)
1 -6-3-5-2-4
Nm at
rls
245/53
240175
235/63
0.8-1 .1 MPa (114-156 psi)
150
kg (330 Ib)
IL ~
j.
~ 1'
129 750
Max torque
kpm at
rlmin
25.0/3200
24.5/4500
24.0/3750
173/37504

70019401960 Specifications
Section
2 B 280 E ngine
General
Group 26 Cooling system
Coolant -compos it ion -gua rantee
Since aluminium is used in ihe engines, active corrosion
protection
is necessary in the coolant to help prevent corro­
sion damage.
Use genuine
Volvo coolant, type C (blue-green ) diluted
with clean water in proportions of 50/ 50. This mixture helps
to prevent corrosion and frost damage.
• Never top-up the cooling system with water alone. Use
genuine
Volvo coolant diluted with clean water in propor­
tions of
50/50.
•
The coolant should be changed every 25,000 miles
(40,000
km) since the corrosion-protective additives in
the coolant lose their effect in time.
• Clean cooling system with solvent (P/N 1161328-8)
prior to
filling new coolant.
litres
Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.0 U S qts
10.5
Expans ion tank
Pressure valve in cap opens at:
overpressure ...................................... .. ..... .
underpressure
............................................ .
Thermostat
Marking .. .................................................. .
Starts opening at. ........................................... .
Fully open at ............................................... .
Fan belts
kPa
150
7.0
87
86-88° (187-190°F)
9l" (20l"F)
Designation, 760. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HC 38 cog x 1075
780.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HC 38 cog x 1100
96
psi
21
1.0

70019401960 Specifications
Section 2 B 6304 Engine
Section 2 B 6304 Engine
Group 20 General.... . . . . . . . . . . . . . . . . . . . . . . . . .. 98
Group 21 Engine............................... 98
Group
22 Lubricating System. . . . . . . . . . . . . . . . . . .. 101
Group 23 Fuel system . . . . . . . . . . . . . . . . . . . . . . . . .. 102
Group 26 Cooling system . . . . . . . . . . . . . . . . . . . . . .. 106
Group 28 Ignition system . . . . . . . . . . . . . . . . . . . . . . . . 107
Group 20 General
Performance , compression ratios, octane requirements
Engine Notes Compres-Octane
Output
type sion
requirement
Ratio
RON· kWat hp at Nm at
rls rim
rls
B6304F 10,71
) 95 150/100 204/6000 267172
Notes:
1) Unleaded fuel only. Can be run on 91 octane unleaded . • RON stands for Research Octane Number, and is a measure of the ability of the fuel to withstand knocking. MON stands for Motor Octane Number, another way of measuring the same property .
(R+M)/2, also called AKI (Anti Knock Index) is a combination of these two measurements . 95 RON is equivalent to 91 (R+M)/2. 91 RON is equivalent to 87 (R+M)/2 .
Other general data
Number of cylinders ......................................... .
Bore .
.................................................... .. .
Stroke .......................................... .......... . .
Displacement ......................... ................ ...... .
Firing order
............................................... .. .
Compression
(normal rating) 1) • ••••• ••••••••••••••••• •.••••••.•
Weight, approx ............................................. .
1) With hot engine, throttle wide open and starter motor cranking at 4.2-5.0 rls (250-300 rIm)
6
83.00 mm (3.268 in)
90 .00 mm (3.543 in)
2.922 dm3 (Iitres)
1-5 -3-6-2 -4
1 .3-1 .5 MPa (184-213 psi)
180 kg (397 Ib)
Group 21 Engine Block
Cylinder head
Max torque
kpm at
rim
27.214300
Height, new ............................... ........... mm (in) 129 .00±0.05
Max machining .............. ......................... mm (in) 0.3
(5.0787±0.0020)
(0.0012)
Max warp:
along ......... .... ................................. mm (in) 0.020
across .................................. ...... ..... mm (in) 0 .008
98

148680
( 150599
150432
70019401960 Specifications
Section 2 B
6304 Engine
Main relay
Volvo part number. . . . . . . . . . . . . . . . . . . . . .. 1 323592-4
Relay , fuel pump
Volvo part number . . . . . . . . . . . . . . . . . . . . . .. 1 362 914-2
Relay , e lectric cooling fan
Volvo part number. . . . . . . . . . . . . . . . . . . . . . . 1 523872-4
105
III II III
iii ,II lit ,II lit